MICRO GUARD RCI 510

Telescopic Boom Cranes

Upgrade Installation and Setup Manual

 NOTICE
SkyAzúl makes no warranty of any kind with regard to this material, including, but not limited to, the
implied warranties of merchantability and/or its fitness for a particular purpose.

SkyAzúl will not be liable for errors contained in this manual or for incidental or consequential
damages in connection with the furnishing, performance, or use of this manual. This document
contains proprietary information, which is protected by copyright, and all rights are reserved.

No part of this document may be photocopied, reproduced, or translated to another language without
the prior written consent of SkyAzúl.

SkyAzúl reserves proprietary rights to all drawings, photos and the data contained therein. The
drawings, photos and data are confidential and cannot be used or reproduced without the written
consent of SkyAzúl. The drawings and/or photos are subject to technical modification without prior
notice.

All information in this document is subject to change without notice.

SkyAzúl, Inc.
16 Walnut Street
Middletown, MD 21769
Fax 301-371-0029
info@skyazul.com

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 Table of Contents
1 Installation ............................................................................................................................................ 1

Introduction .............................................................................................................................................. 1

1.1 System Information....................................................................................................................... 1

1.2 Upgrade Parts: .............................................................................................................................. 2

1.2.1 A450769 Computer Assembly............................................................................................... 2

1.2.2 A450251 RCI 510 Display ...................................................................................................... 2

1.2.3 A240690 Reeling Drum ......................................................................................................... 3

1.3 Computer Wiring........................................................................................................................... 4

1.4 Units with Swing Switches ............................................................................................................ 6

1.5 Removal and Installation .............................................................................................................. 7

2 Operation .............................................................................................................................................. 9

Outline of Operation ................................................................................................................................. 9

2.1 System Setup............................................................................................................................... 11

2.1.1 Required Tools .................................................................................................................... 11

2.1.2 Crane Configuration ............................................................................................................ 11

2.1.3 Entering Setup Mode .......................................................................................................... 12

2.1.4 Checking for Error Codes .................................................................................................... 13

2.1.5 Zero for Extension ............................................................................................................... 13

2.1.6 Setting Zero for Boom Angle ............................................................................................... 14

2.1.7 Adjusting the displayed “0” to match the actual “0” on the leveling tool.......................... 15

2.1.8 Entering a Span ................................................................................................................... 16

2.1.9 The Entry Screen ................................................................................................................. 17

2.1.10 Setting the Rope Limit Option............................................................................................. 18

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MICRO GUARD® RCI 510 – Upgrade Installation and Setup Manual 1

1 Installation

Introduction

The MicroGuard MG510 replaces the previous Terex MG404, 414, and RCI 500 system
currently using the obsolete MG400 computer. This section will cover the necessary installation
instructions for the MicroGuard 510 using the new 500 series computer.

Please read the Operator’s Manual carefully before operating the system. The system installer
must be knowledgeable in safety guidelines, crane capacity information, and the crane
manufacturer’s specifications.

For questions about Installation, please contact Technical Support:

SkyAzúl, Equipment Solutions

200 W. Main Street, Suite, 2A
Middletown, MD 21769
Fax 301-371-0029
info@skyazul.com

1.1 System Information

When installing the new computer and display, Greer Company recommends the existing
rectangular shaped reeling drum be replaced with our current production reeling drum,
A240690. The rectangular shaped reeling drum is obsolete. There is no longer field support for
this product.

Installing the new reeling drum will ensure field support and parts support in the future. The
A240690 reeling drum is equipped with mounting brackets and electrical fittings to be a direct
replacement.

The new computer uses Flash RAM technology for loading the Duty Files. If known at the time
of purchase, the proper Duty File will be loaded on your computer before being shipped.

Kit K758743 is available for preparing the new flash-style computer for use. The kit contains a
programming cable, a CD with the necessary software, and a PDF copy of the instruction
manual to allow the installer to load the correct Duty File on the computer.

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1.2 Upgrade Parts:

1.2.1 A450769 Computer Assembly

Where applicable, the computer assembly includes a wiring harness designed to integrate with
the existing Terex crane wiring harness where applicable. Refer to the installation drawing
below.

1.2.2 A450251 RCI 510 Display

The display is designed specifically for upgrading Terex cranes and operates with Terex-style
menus.

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1.2.3 A240690 Reeling Drum

If you replace the existing reeling drum with A240690, the installer must replace the guides for
the Anti-Two-Block cabling. The guides support the level wind system of the reeling drum. The
part number for the new guide kit is K056005 and includes the new guides and installation
instructions. The instructions detail how to obtain the best reeling drum performance.

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MICRO GUARD® RCI 510 – Upgrade Installation and Setup Manual 4

1.3 Computer Wiring

The RCI 510 System is based on the original wiring done by the factory. Greer Company cannot
assume responsibility for color codes used on wiring done at the time of origin.

We have identified the wiring inside and outside of our computer to assist with the installation. It
is the responsibility of the installer to properly identify the correct wires and routings on the
crane for connections to the MG510 computer. Please reference the wiring diagram below.

NOTE: The Green wire may have been replaced by a jumper wire inside the MG400 computer
from B+to Relay 2 C. In this case, use a jumper wire from BLD 3 to BLD 7.

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Computer Wiring Connections

Connection Connection
A450663 A450763
JP3-1Battery 0V BLD 1 Battery -VE
System Power JP3-2 BLD 2 Battery +VE
JP 5-1 Relay Power Feed BLD 7 Relay Power
Feed
JP 5-2 Solenoid Output BLD 8 Solenoid Output
Work Instruction
Connect to Frame Ground
Connect to Crane Power 12V - 36V
(Fused at 10 Amp power source)
Power for Function Kickout
Power to Function Kick Out Solenoids
on Crane

Connection Connection Work Instruction

A450663 A450763
JP 12-1 (Data "A") BLD 38 (Data "A") Display Communication connection
JP 12-2 (Data "B") BLD 39 (Data "B") Display Communication connection
JP 12-3 Reset BLD 40 Reset Reset line…..Usually Blue
JP 12-4 Display Power BLD 41 Power 12V Power for Display
JP 12-5 BLD 42 Ground Display Ground Wire

Connection Connection Work Instruction

A450663 A450763
JP9-1 BLD 26 Digital Input (12V)
JP9-2 BLD 27 Digital Input (12V)
JP9-3 BLD 28 Digital Input (12V)
JP9-4 BLD 29 Digital Input (12V)
BLD 30 12V Power Supply

Connection Connection Work Instruction

A450663 A450763
JP11-1 BLD 34 Drive Voltage for Swing Pot
JP11-2 BLD 35 Ground Signal for Swing Pot
JP11-3 BLD 36 Communication Connection
JP11-4 BLD 37 Communication Connection

Connection Connection Work Instruction

A450663 A450763
JP8-1 BLD 20 Monitored Voltage Signal Anti 2 Block
JP8-2 BLD 21 Analog Signal from Ext. to Computer
JP8-3 BLD 22 Analog Signal from Angle to Computer
JP8-4 BLD 23 Monitored Voltage Signal Anti 2 Block
JP8-5 BLD 24 Drive Voltage for Swing Pot
JP8-6 BLD 25 Internal Ground (Drive Voltage)

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1.4 Units with Swing Switches

Some older units in the field may use swing switches instead of swing potentiometers. Refer to
the appropriate work area schematic.

Description Connection Connection Work Instructions

A450763 A450763

Rear BLD 20 DIN 0 Digital 0V

Side BLD 27 DIN 1 Over Side Chart

Front BLD 28 DIN 2 Over Front Chart

Between Tires BLD 29 DIN 3 Between Tires Chart

Power BLD 30 VP+ Switched Power

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MICRO GUARD® RCI 510 – Upgrade Installation and Setup Manual 7

1.5 Removal and Installation

1. Place the crane in rigging mode and raise the boom. This will allow access to the hose
fittings and wiring harness connections.

NOTE: Leave the power and FKO cables connected to allow movement of the boom during the
removal and installation process.

2. Disconnect the reeling drum cable.

3. Disconnect the swing sensor.
4. Remove the display.
5. Remove the display cable.
6. Unscrew the four bolts and remove the old computer from its mounting place. Place the
computer on the deck.

NOTE: Do not disconnect the power and FKO cables.

7. The new computer is smaller than the existing one. Mount the new computer using one
of the existing bolt holes. Use the new computer as a template to drill three new
mounting holes.
8. Screw in the remaining bolts. Ensure the computer is securely attached.
9. Lower the boom completely. Remove the exisiting pressure hoses from the old
computer.
10. Install the new pressure hoses and retain the velocity fuses.

NOTE: Install the velocity fuse in-line with the base-side pressure sensor. Ensure there is
sufficient length for boom travel without stretching or damaging hoses.

NOTE: Install bleeder fittings at the cylinder. Obtain the fittings from your hose dealer.
WARNING!
FAILURE TO ENSURE THE VELOCITY FUSE IS CORRECTLY INSTALLED MAY
CAUSE A DANGEROUS UNCONTROLLED, DOWNWARD MOVEMENT OF THE
BOOM IN THE CASE OF HOSE FAILURE.

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11. Connect the new pressure hoses to the new computer.

12. Raise the boom.
13. If using the rectangular reeling drum, disconnect the reeling drum cable and remove.
The new computer is wired with a new cable and only needs to be attached to the
reeling drum.
14. Install the display.
15. Install the display cable.
16. Install the power and FKO cables to the new computer.
17. Slowly elevate the boom to its maximum angle to ensure the pressure hoses and
electrical cables are properly routed.

WARNING!
ENSURE THE PRESSURE HOSES AND ELECTRICAL CABLES ARE ROUTED
PROPERLY. IF MISROUTED, WHEN THE BOOM IS RAISED THE 1ST TIME THE
HOSES/CABLES CAN BE DAMAGED OR DESTROYED.

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MICRO GUARD® RCI 510 – Upgrade Installation and Setup Manual 9

2 Operation

Outline of Operation

SYSTEM COMPONENTS

 Microguard® RCI 510 Display Unit

 Microguard® RCI 510 Computer Unit
 Pressure Transducers
 Extension Reel with length and angle sensors
 Anti 2-Block (ATB) switches
 Cables
 Installation/Operator Manuals

The MICROGUARD® RCI 510 System continuously monitors the load and warns of an approach to an
overload or Two-Block condition. Crane functions are monitored by means of high accuracy sensors. The
system continuously compares the load suspended below the boom head with the crane capacity chart
stored in the computer memory. At approach to overload, the system warns by means of audible and
visual alarms. The system can be configured to cause function kick-out by sending a signal to function
disconnect solenoids.

DISPLAY
The Microguard® RCI 510 System continuously displays:
 Rated Load
 Actual Load
 Bar Graph showing Percentage of Rated Load
 Radius of the Load
 Boom Angle
 Main Boom Length
 Working Area
 Crane Configuration

On-screen messages provide visual warnings of conditions that occur during operation of the system.

BOOM ANGLE SENSOR

The Boom Angle Sensor is a magnetically dampened potentiometer that measures the angle of the
boom.

EXTENSION SENSOR
The Extension Sensor measures the length of the boom. It is located inside the Extension Reel cover.

PRESSURE TRANSDUCERS
The pressure transducers measure pressure in the boom hoist cylinder. the signal is then processed to
provide a continuous display of the total load suspended below the point of lift.

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ANTI TWO BLOCK (A2B)

The ®Anti Two Block system provides protection by preventing pulling the load block into the head of the
boom and causing structural damage to, or breaking the lifting cable. The system, when activated, will
prevent movement of any function that could further cause the condition to become unsafe. (Boom Down,
Winch Up, Boom Out.)

OPERATOR SETTABLE ALARMS

Operator Settable Alarms provide work area protection zones, warnings for various job site conditions,
and alarms for overhead obstructions.

These alarms include:

 Max and Min. Boom Angle
 Max and Min. Boom Extension and Boom
 Tip Height.
 Work Area and Exclusion Zone Alarms.

Note: Operator Alarms do not cause function lock out to occur.

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MICRO GUARD® RCI 510 – Upgrade Installation and Setup Manual 11

2.1 System Setup

The Microguard® RCI 510 system contains a setup calibration mode that operates through the system
display console. The setup mode provides a means of ensuring that the system sensors are correctly
positioned and adjusted following system installation or parts replacement.

This procedure assumes that installation of system components, cabling, and hydraulic connections have
been successfully completed and checked.

The setup procedure involves only the sensors mounted within the extension reel on the side of the
boom.

It is important that each step of this procedure is properly followed for the system to accurately provide
load, rated capacity, warnings, and kick out functions.

WARNING!
At all times, observe safe practices.
Make sure that crane capacity limitations are
understood, and that the crane capacity plate is
followed. Do not exceed manufacturer's specified
lifting limitations.

2.1.1 Required Tools

For Setup: Phillips Screwdrivers, Bubble Level – Accurate to 0.1° at level
For Testing: Inclinometer – accurate to 0.2°, Mearuring tape (100 ft) – fiber‐type with tenths of feet

2.1.2 Crane Configuration

Before starting the system setup, position the crane on firm and level ground with the outriggers properly
extended and set. It is recommended that the crane be configured with no stowed or erected jib (bare
boom) and reeved with a single part-of-line.

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MICRO GUARD® RCI 510 – Upgrade Installation and Setup Manual 12

2.1.3 Entering Setup Mode

The display will step through each setup operation, as required by the user. During the setup procedure,
the display console should be placed in a position that allows easy viewing while adjustments are being
made within the boom extension reel, and allows for operation of the display buttons. The setup mode is
activated by the following procedure:

1. Press the Test and Operator Alarm

Buttons simultaneously and the
Microguard RCI 510 console will request a
security code be entered in order to get
into the calibration routine. You will then
have 5 seconds to enter the proper button
pushing sequence, and when this is done,
the information screen will show “Entering
Calibration Mode”.

2. When the system asks for the

Calibration Entry Security, the
following entry must be made within 5
seconds in order to be allowed
access to the calibration routines.
1. Upper Left
2. Lower Right
3. Lower Left
4. Upper Left

If this entry is not completed within 5 seconds, the system will revert to a “Normal Operating Screen”. The
first screen to appear after the entry into the calibration mode will be the error code screen. This screen
will have error codes lined up across the bottom of the information screen like the illustration on the next
page.

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2.1.4 Checking for Error Codes

All error codes should be “0”’s, and the Duty

Chip number should appear, as well as the
serial number of the computer system
installed on the unit. The button adjacent to
“Exit” will take you back to the main menu.

Why Zero and Span?

In order for the computer to accurately measure length and angle, we must insert accurate start and stop
points for it to measure from and to. To accomplish it the Microguard® RCI 510 display uses a very
simple menu system for the calibration. The Menu screen is arranged so that the 4 keys surrounding the
information screen can be used as function select buttons.

The menus used in the setup calibration are as follows:

 Menu 2- Zero Sensors
 Menu 3- Span Sensors
 Menu 4- Swing Pot Calibration

The menu in use is noted at the top of the information screen. You must use the menu up and menu
down function to first locate the menu number and the sensor number to assure that you are calibrating
the proper sensor. Sensors for the system are as follows:
 Sensor 2 = Boom Extension
 Sensor 3 = Boom Angle

In order to calibrate the system, the unit should be set up on firm level ground and the outriggers at their
fully extended position. It is acceptable for the Side-Folding Jib to be in place, as long as it is noted in the
display setup as a stowed jib. For the first steps of the calibration procedure set the boom at 0° (perfectly
level), using a digital level that is accurate within .1° degree. The boom should be fully retracted.

2.1.5 Zero for Extension

Start the unit and put the console into the

calibration mode and menu up until your
“02 Zero Sensors” menu is on the right
side of the information window. Press the
upper right button and the “Zero No. 2 =
XX” will appear as in the illustration at the
right.

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MICRO GUARD® RCI 510 – Upgrade Installation and Setup Manual 14

Remove the cover from the reeling

drum and locate the extension sensor.
Rotate the Extension Sensor gear
Clockwise, until the clutch clicks and
then rotate to the left until the number
adjacent to the “Zero No. 2” in the
information screen equals “0” as in the
picture below.

Press the upper right button adjacent to

“Zero NO. 2” and the display should
verify that you want to calibrate the
extension “0”. (YES! CALIBRATE!)
Pressing the button a second time will
cause the number to the right of “Zero
No. 2” to go to “0”, and the extension
zero is finished. The retracted boom
length should appear in the boom
length window as in the picture at the
right.

2.1.6 Setting Zero for Boom Angle

Press the Menu Up Button and the display

will scroll up to “Zero No. 3”, which is the
Angle Sensor. With the boom still setting at
the 0° level, we must next set the zero
calibration in the display. The display
should look like the illustration to the right.

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MICRO GUARD® RCI 510 – Upgrade Installation and Setup Manual 15

2.1.7 Adjusting the displayed “0” to match the actual “0” on the leveling tool.

Using a digital volt meter, check the voltage

reading between the blue wire on the
terminal (negative) and the Green Wire
(positive). The voltage should read between
.470 and .475 Volt. If this reading is not
within the tolerance, you may have to adjust
the angle potentiometer to get the correct
voltage reading.

The potentiometer may be rotated in its

mounting by loosening the two attaching
screws just enough to allow rotation of the
pot. When the “0” is reached on the display,
the screws must be securely retightened.

Note: This device is very sensitive, so it should be rechecked after retightening to make sure the reading
didn’t move.

Once the level and the display agree, you may proceed with the zeroing process in the calibration screen
on the Microguard® RCI 510 display.

Press the upper right button adjacent to “Zero

NO. 3” and the display should verify that you want
to calibrate the boom angle “0”. (YES!
CALIBRATE!) Pressing the button a second time
will cause the number to the right of “Zero No. 3”
to go to “0”, and the extension zero is finished.
The retracted boom length should appear in the
boom length window as in the picture at the right.

With this part of the procedure completed, you

should be able to move on to the “Spanning
Routine”, which is menu No. 3 on your display.
Press the button next to exit in the zero spanning
routing. Using the Menu Up and Menu Down
buttons on the display, press menu up until the
display looks like the screen at the right. Pressing
the button by the 03 Span Sensors menu, will let
you enter the screen for spanning operations. The
screen should then appear like the screen on the
following page.

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The functions of spanning the boom, includes actions that

necessitate full boom extension, so you must maneuver the boom
into a boom angle that will allows you to safely extend the boom to
the fullest length. (Usually above 65°)

You must take precautions to avoid overhead power lines and

any other obstructions that may exist.

Remember to have the proper numbers to enter for the “Extension Span” before starting the spanning
routine. The retracted boom length should already be showing in the boom extension window after the
extension function has been “zeroed”. The span measurement, if not available must be measured as
follows:

With the boom fully extended measure from the centerline of the boom hinge pin to the centerline of the
boom head sheave. This measurement should then be deducted from the retracted length shown in the
boom length window.

EXTENDED BOOM LENGTH – RETRACTED BOOM = BOOM SPAN

2.1.8 Entering a Span

After the boom span “number” has

been determined, you may raise the
boom and fully extend and proceed to
the “Span No. 2” window on the
console. Pressing the upper right
button on the information window will
produce a screen that looks like the
screen at the right. Pressing the upper
right key will produce a message: “Yes
Calibrate”. When the button is pressed
a second time the unit will again
change screens and give you an entry
screen for the Extension Span as
shown on the following page.

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2.1.9 The Entry Screen

The entry screen for both Extension
and Angle span look identical. So
you need to be careful of which
function you are working with.

The “Span Entry Window” will look

like the example at the right. Note a
pair of brackets ( [ ] ) at the upper
right hand side of the screen is the
location where the numbers to be
entered will be temporarily stored.
The numbers in the bracket are
entered into the bracket using the
left upper key. You must always
enter decimal points in the numbers,
even if the number is an even
number (like 75.0). You would still
add the decimal.

The two lower keys are used to scroll between the number values shown on the screen. (Note: The
number blinking between the < > brackets is the number that will be entered between the ( [ ] ) in the
upper right portion of the screen) When the desired numbers are entered between the ( [ ] ), and the
upper right key is pressed to calibrate, the proper span will be installed into the computer’s memory, and
the correct extended boom length will them appear in the boom length window. As shown in the example
below:

It is advisable to retract the boom and

recheck the extension “0”, and then re-
extend the boom to double check the
extended number again.

With this accomplished, press the Menu

Up button again and the screen will
move to “Span No. 3 = XX.X”.

The same instruction as above applies

for the number entries for the boom
angle span. The only difference is that
this time you will be entering the
numbers in degrees and 1/10’s of a
degree, and the information will be
taken from the reading on the digital
level on the boom.

With the boom at 65° or above read the level and enter the exact angle reading from the level. When the
information is entered into the ( [ ] ) brackets, press the upper right hand button to calibrate the input. The
boom angle window on the display should agree with the level. Lower the boom to another angle (say
45°) and be sure that the reading still agrees with the level within +- .2 of a degree. At this point, it is an
excellent idea to manually check the radius and compare the actual radius with radius displayed on the
MICROGUARD® RCI 510 console. This should agree within .5 of a foot. (Or approx. 6”).

Before load testing the unit, we must complete one more step in the calibration procedure and that is to
calibrate the swing pot, so the computer can recognize where the upper turret structure is in relation to
the Sub Frame structure.

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MICRO GUARD® RCI 510 – Upgrade Installation and Setup Manual 18

The boom on the unit should be fully retracted and the boom centered and stowed in the boom rest. This
will become the “0°”, or stowed position in the boom swing arc.

In order to calibrate zero you will need to put the MICROGUARD® RCI 510 console back into the
calibration mode, and menu up until you reach “Menu 04 Swing Potentiometer”.

Press the upper right key around the

information screen and the display will look as
show in the example.

With the boom stowed as per the instructions

above, the display should be showing either
360° or 1°. With this set, pick the boom up out
of the boom rest and rotate a few degrees to
the right. The numbers should start counting
upward, 1, 2, 3, etc.. If this does not happen,
press the Menu Up button and the screen
should change to read Direction = ( + or -). By
pressing the upper right hand button the
reading should change to the opposite
direction, and the swing zero is complete.
Press the button adjacent to Exit on the
screen and you will return to the calibration
screen menu.

2.1.10 Setting the Rope Limit Option

When the crane has the option of different cables with different rope limits, it becomes necessary to reset
the cable limit to facilitate this. The final step in the initial or setup calibration to setting the cable size that
is in use on this unit.

To set this important factor, press the Menu Up button until “Menu 10 Rope Limit” is reached, and press
the button on the upper right side of the information screen.

This will move the screen to the CURRENT

ROPE LIMIT = XX.X as per the example at
the right. In order to change the rope limit
as needed, the upper right hand button will
be pressed once and the screen will
change to reflect the new Cable rope limit.
Press the exit button to return to the
calibration menu and once more to reset
and the system will go through the self-test
mode and come up in the “Normal Mode”.

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 SkyAzúl, Inc.
16 Walnut Street
Middletown, MD 21769
Phone 301-371-6126
Fax 301-371-0029
www.skyazul.com info@skyazul.com

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